Arc Welding Current Profile for Spatter and Micro-Short Suppression
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Solution Overview
Problem
In arc welding using a shield gas with carbon dioxide as a main component, the initial increase in welding current causes significant vibration of the molten pool, leading to micro-short circuits and increased spatters.
Innovation Solution
An arc welding control method that alternately repeats short-circuit and arc periods with a constant wire feeding speed, involving specific current control gradients and periods to manage the welding current, including increasing it to a first value, reducing it to a second value, then increasing again to a third value before rapidly reducing it to minimize molten pool vibration and spatters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the welding current is increased at the initial stage of the arc period, then the occurrence of short circuit is suppressed, but the molten pool vibrates greatly causing micro-short circuit and increasing spatters
Solution Approach 1:
The welding current is controlled to vary periodically within the arc period, transitioning through multiple stages: initial increase to prevent short circuit, then reduction to suppress molten pool vibration, followed by increase to third current value and rapid reduction. This periodic current variation resolves the contradiction by applying different current levels at different times to achieve both short circuit suppression and spatter reduction.
Solution Approach 2:
The welding current is dynamically adjusted throughout the arc period rather than maintained at a constant high level. The current transitions through multiple values (first current value, second current value, third current value) with specific gradients and timing, allowing the system to adapt to different stages of the welding process to prevent both short circuits and spatters.
2Stability of the object's composition
If the welding current is increased to suppress short circuit, then arc stability is improved, but molten pool vibration is amplified causing more spatters
Solution Approach 1:
The welding current follows a periodic pattern with distinct phases: initial increase for arc stability, reduction to minimize vibration energy, then increase to third current value and rapid reduction. This periodic variation maintains arc stability while controlling molten pool vibration energy to reduce spatters.
Solution Approach 2:
The welding current parameter is changed multiple times during the arc period, transitioning through different current values and gradients. The current is increased to first current value (200-300 A), reduced to second current value, increased to third current value, then rapidly reduced. These parameter changes allow simultaneous achievement of arc stability and vibration suppression.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method effectively reduces spatters during arc welding by suppressing molten pool vibration and micro-short circuits, stabilizing the arc and improving welding quality.
Implementation Method 1
a molten pool greatly vibrates due to an arc force acting on a droplet during globular transfer
Data Source
Figure 1
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Figure 3A~3D
AI summary
Provided is an arc welding control method for performing control in an arc period, the control including: first control of increasing welding current (Ia) to first current value (I1) in a range from 200 A to 300 A inclusive at first gradient (S1) and maintaining welding current (Ia) at first current value (I1) for first period (T1); second control of reducing welding current (Ia) from first current value (I1) to second current value (12) at second gradient (S2) and maintaining welding current (Ia) at second current value (12) for second period (T2); third control of increasing welding current (Ia) from second current value (12) to third current value (13) higher than first current value (I1) at third gradient (S3); and fourth control that is started to reduce welding current (Ia) from third current value (13) within 0.5 ms after welding current (Ia) reaches third current value (13) under the third control.